BENDING PLASTIC
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Polycarbonate is a transparent and strong thermoplastic. Its outstanding toughness means it can be bent. We can do cold line bending or hot line bending, which requires heat to bend or mold a polycarbonate sheet. To heat the polycarbonate sheet evenly, we use a device designed for heating plastic. A heat line uses an electric current to create heat.
One of Excelite’s main services is machining acrylic or polycarbonate products according to customer’s requirements. From fabrication to sheet production-project solutions, Excelite can do them all. Bending is one of the most popular services. We can quickly produce your product based on your prototype, and have it ready for shipment. We can control the process to approach zero errors. Our production workers, staff, and sales team are all experienced and well trained.
Types of Bending Plastics
Curved plastic is used in many different products and in a wide variety of sectors.
There are several types of bending plastic. The bending process can be carried out either by heat or cold bending. The choice of method depends mainly on the material, the end use and the aimed for quality.
The types of bending plastic sheets including:
Heat Bending:
Using heat to soften the plastic sheets, allowing it to be shaped and bent into the desired form. We found the best undergo heat bending materials are acrylic (PMMA), polystyrene, polycarbonate, PETG, PET and ABS.
When bending acrylic sheets, the hot wire/line bending is warmed to 100-150 degrees.
The material suffers no damage as a result of the heat applied to it. While treated by heat bending, the acrylic is equally strong after it has cooled, almost as if it had been cast in its final shape.
Cold Bending
It involves applying pressure to bend plastic sheets at room temperature, ideal for materials up to 4mm thick and suitable for certain thermoplastics like polycarbonate.
Common applications include skylights, machine guards, and transparent walkway ceilings.
V-Bending
A method where plastic is bent in a V-shape, often used for creating sharp corners.
If we bend thicker panels, more than 4.5mm sheets, we recommend to back routing or V-grooving along the bend line.
Roll Bending
Using rollers to gradually bend the plastic into curves, commonly used for large sheets.
Form Bending
Bending plastic over a mold or die to achieve specific shapes and details.
Slot Bending
Cutting a slot into the plastic before bending it, allowing for a tighter bend without cracking.
These are not common bending method. Each method has its own applications and is chosen based on the type of plastic, the desired shape, and the project requirements.
The Pros and Cons of Bending Plastic
Pros Of Bending Plastic
- Affordable method to shape plastic sheets, reducing expensive mold costs
- Offers uniform precision
- Compatible with most plastic materials
- Bending performed after printing, lowering printing costs
Cons Of Bending Plastic
- Limited to bend complex multiple projects
- Some materials spring back
- Limited thick material
Polycarbonate Limitations
To bend polycarbonate, flanges must be overbent to achieve the desired angle due to the spring back of the material. This means that some designs that can be formed in sheet metal may not be feasible in plastic.
In the example shown here, the material is bent 120-130 degrees to achieve a 90-degree angle.
Polycarbonate
- Polycarbonate parts will have a +/- 5-degree bend angle tolerance on bends up to 24″ long
- Polycarbonate parts will have a +/- 7-degree bend angle tolerance on bends longer than 24″
- Polycarbonate parts are limited to up to 3 bends or flanges per part.
- Polycarbonate bends can be no greater than 90° and no less 45°
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The versatility and cost effectiveness of the plastic thermoforming process make it an ideal choice for a wide array of industry applications. Plastic thermoformed parts are commonly used to replace fabricated sheet metal components and also offer some unique advantages over parts constructed with FRP manufacturing processes. Whether your project is a new design or a process conversion from an existing one, thermoforming your components with Excelite can be an ideal solution for countless applications and industries.
A tool cabinet, designed with advanced bending machining and drilling processes to ensure precision and efficiency.
Why Work With Us
With over 15 years of polycarbonate fabrication and machining experience, Excelite specializes in the fabrication of polycarbonate and acrylic sheet products, ensuring top-notch quality and precision. We are committed to providing the best manufacturing solutions tailored to your unique requirements.
Whether you have a detailed drawing or just an idea, our team of professionals is ready to turn your vision into reality. Enjoy the benefits of our services, including:
In-house Design & Tooling
Exceptional Accuracy (+/- 0.005″ Tolerances)
Comprehensive OEM & ODM Services
ISO 9001:2008 Certification
Direct Manufacturer Advantage
We invite you to partner with us and experience a seamless, efficient, and quality-driven production process.
TAILORED POLYCARBONATE SOLUTION
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